KiwiSAT, Status Report

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Progress report - Reviewed - 23 May 2009

by Fred Kennedy ZL1BYP – KiwiSAT Project Leader

As in the past I will follow the headings from the last report and fill in the details.

Despite the drain on our resources as we near completion, our funding continues to support current progress. The final push to an orbital unit does, however, requires that final financial support. Apart from the cost of the launch, our money requirements are modest and the continuing donations are enabling us to complete the work. We'll be putting out of list of the final modules and inviting individuals and groups to take ownership of these financially, so they can have the satisfaction of knowing what they have supported.

Any financial support you can give will certainly help us to produce – for all radio amateurs - another versatile amateur radio satellite. KiwiSAT will also provide some quite interesting experimental work if supporting that would be of interest to you.

Certainly ‘space grade’ materials/components etc. (which we can usually identify) are constantly in demand for the various systems and any help to locate – in small quantities - and ship items to us, would help us a lot. It would also help keep our costs down. I’ve lost count of the number of times the price of the item is dwarfed by the cost of some “Super Swift International Courier Delivery” service that many companies now “mandate” as their shipping method! Gone are the days of slipping things in an envelope and sticking a stamp on it – which is all most bits (and our delivery timescale) require.

Back to the Status!

 

U band and L band/GPS antennas.

Despite several changes all are now flyable units and we have the necessary splitters and phasing loops to link them to the receivers.

The late decision to fly an additional beacon (U band) required some changes to the U Band antennas. There is insufficient room on the bottom (Z-) face to use a measuring tape based stub and both U band antennas are now brass tubes fitted into TNC connectors.

These, and the L band folded dipoles are now plated, assembled and tested, and await final integration.

The V band antennas are unchanged using "measuring tape". They remain normal to the bottom plate sides and will be at 45 degrees to the bottom face when in flight.

The GPS Receiver has its own patch antenna. A non-problem.

Completion date = Completed.

 

The Horizon Sensor

The identification of a thermopile I/R sensor in a TO-5 can that has not only a “U/V proof” (silicon based) diffractive lens but also an in-built FOV restrictor for 9 degrees has prompted a change to the sensor head.

The single (U/V plus visible) light head has been replaced by individual units with a small weight saving – always valuable. 

Clayton (ZL3TKA) has completed the PCB’s and assembled and tested the units.

These two units are being delivered at time of writing.

Completion date = Completed.

 

The Sun Sensor

One (protoflight) Sun Sensor head using a Hamamatsu PSD - type S5991-01 - has been operational for several years using sub standard PCB’s as breadboard.

Thanks to Tim - a painstaking member of Phil’s staff at TMD Consultants here in Auckland, the heads have been wired with new PCB’s and Clayton (ZL3TKA) has now completed the redesign and build of the Sun Sensor main electronics PCB. 

The unit is currently being tested and all that remains to be done is to set the various output levels using fixed resistors. They are scheduled to be complete for integration into the flatsat at the Christmas break.

Completion date = Completed.

 

The Camera

The camera is now complete and tested and pictured below. Some work on the software is in hand but hardware is ‘all systems go’!   Again – thanks Clayton (ZL3TKA) & Mark (ZL3JVX) for the early development work.)

 

 

To check quality, Clayton photographed this Kiwi Olympic mascot. Note that the pictures shown here have 50% JPEG compression so are an indication only of expected final definition.

First flight unit to hand and integrated in the Engineering Model. Second unit is currently being assembled.

Completion date = imminent.

 

GPS Receiver

Kelvin (ZL2KB)’s GPS receiver has been completed and 3 flyable units are now to hand. They have been fully tested using a professional GPS simulation system with little to choose between the 3 units. The most sensitive has been earmarked to fly.

The flight and stand-by flight units have been in the vacuum chamber for 72 hours and baked-out at 60º Celsius for 24 hours during that period.

Completion date = Completed.

 

L Band Converter

The protoflight L-Band down converter (pictured) has been assembled and tested. Some Local Oscillator chain problems were found and are being investigated. This has resulted in delays to the flight standard unit.

The modified protoflight board was expected to be available for soak testing in the flatsat over the Christmas break.

Work on this system has now stalled and steps have been taken to redirect efforts to bring the development to an early conclusion and complete the unit without further delay.

Completion date = Rescheduled!

 

FM Receiver.

Mark (ZL3JVX) has produced a protoflight FM Rx and this has been fully tested and proved. This fine piece of work is now being repeated and four more units will be required – two of which will fly. This will enable us to have a spare Working Channel receiver and a spare Command Receiver.

The PCB’s, boxes and most of the parts for the first two are to hand. Parts for the second two are being ordered and the units will be professionally assembled.
(It’s worth noting that the prototype unit was totally un-phased by a long spell heated to 50° Celsius in the Massey vacuum Chamber at -6 Torr pressure! The units will be subjected to formal bake-out tests at 60ºC idc.)
First two of four two flight units completed and to hand. Two more are under final completion. The delay in the delivery of these two units is not affecting the completion of the flight

Completion date = Back-up units only - priorities rescheduled - .

 

Linear Receiver (and Pre Amp)

As mentioned in the last report, the U/V Linear Transponder is up and running. The final flight version is all ready to go having had its levels checked with the new combined pre-amp/splitter that Phil has designed and built. The combined pre-amp splitter has resulted in a significant saving in weight and size as – with minor changes to the lid it all now sits in the original “pre-amp” milled box. It is currently running round the clock from Whangaparaoa, North of Auckland on the high gain antennas at ZL1BYP’s shack. Best performance has been a CW contact to the Mount Egmont area – 295km away down South. Not bad on 4 Watts.

(Our thanks to Phil Wakeman of TMD Consultants for this superb piece of work. It was the first fully completed and tested system for KiwiSAT.)

Completion date = Completed.

 

Magnetometer

A Honeywell HMC 2003 (3 axis) Magnetometer will be flown and this has been fitted on a PCB designed and built by Clayton (ZL3TKA) as shown below. The magnetometer system – together with the reset facility – has been fully tested and is awaiting software and integration into the flatsat. First flight unit is to hand and ready for integration.

A back-up unit is being built as a pre-flight spare.

Completion date = Completed.

 

The Integrated Housekeeping Unit (IHU) Mk-2 Computer

The complexity of the IHU Computers is such that we have had them professionally assembled. A revolutionary inter board connector system has been used which allows for system development (there are a few option links that must be correctly selected) and final hard connection without compromising reliability. Forward Error Correction has been incorporated in the flight units.

Thanks to Ian (ZL1AOX), and Austin, who is responsible for the programming, the Flight versions have been fully tested and await software development - an ongoing activity.

The accompanying PCB pictured in the flatsat tray (below) is one of the flight units. Boot and (second) reset ROMs will be fitted once initial flight software has been proven.

Our thanks to the Howick Radio Club for the generous donation that has made the new Mk-2 IHU possible. (Truly superb, guys.)

Completion Date = Completed awaiting software development.

 

The Battery

A complete flight battery of NiMH cells – obtained via AMSAT-DL (Thanks for making them available, guys) – is available and they are matched for flight. The cells, (10 in number) 4000mAh from Suppo in China – will be fastened down to support frames which are already machined from flight acceptable plastic (Delrin).

The appropriate Kapton tape has been obtained and the existing heat shrink insulation around the cells will be replaced with this before fitting. (An out gassing precaution!) The outfit will then be ready to go into the thermal vacuum bake-out chamber.

The battery compartment also features the Z Axis torque coil and the coil driver PCB’s for all three coils for the active ADAC system. The coils have now been finally sized and wound and – as with everything else for KiwiSAT – have been subjected to a thermal bake-out in the vacuum chamber. The PCB’s for the coil drivers have been populated and tested and Clayton (ZL3TKA) has some software underway to ensure the coils – which would quickly drain the battery if stuck “on” – are fail safe.

Completion date = Completed.

 

The Battery Charge Regulator

Work on the Battery Charge Regulator undertaken by Hans (ZL1HB) is now complete and selected units earmarked for flight and for standby. This vital heart of the satellite is receiving full attention to ensure maximum battery life for our KiwiSAT.

The flight unit has been baked in the vacuum chamber and re-tested on Hans’ purpose built test rig (pictured to the right).

The completed Battery Charge regulator is pictured here as it was about to be placed in the Massey University thermal vacuum chamber.

All units undergo testing in this vacuum chamber which has been built specially for KiwiSAT but available for other work at Massey University in Albany.

Completion date = Completed.

 

Transmitters

The FM Transmitter protoflight unit (designed by Kelvin, ZL3KB) is complete and has been tested under normal and vacuum conditions. It performed very well but a perceived need to improve its overall efficiency and the removal of some spurious emissions close in to the carrier, together with a need to provide a phase related signal source for the new 70CM beacon has prompted a revision of the PCB. Kelvin (ZL3KB) has returned from a few months ‘globe-trotting’ is undertaking the task. This unit is held ready for insertion in the flat-sat.

As mentioned above, Phil’s Linear Transmitter (married with its Rx and Pre-amp) is finished and on trial beaming South from Whangaparaoa, 25k North of Auckland. It is now awaiting integration into the space-frame.

Completion date = Completed.

 

70CM Beacon.

Unforeseen delays have been incurred requiring a reallocation of tasks for the development of this vital sub-system to ensure early and reliable completion.

Completion date = Early May.

 

Power Switches

Two power switches that will be held open by a projection on the launch adaptor are situated in the Transmitter tray. Mil Spec. micro switches of the same type as used (successfully!) in the original Microsats are held for this task.

Completion date = Completed.

 

The Structure

Work on this has taken several forms with models, wooden mockups, prefabricated aluminium trays (‘engineering mock-ups’) with drawings/sketches by the dozen in support. Mike Jack of Stanier Engineering – our CNC machining expert – has completed the machining of the trays from 6061-T 651 aluminium blocks. The material was readily available from a supplier in South Auckland and work proceeded with little delay.

A lot of aluminium disappeared during the machining. See also an animated view of the structure here on YouTube.

Magnanimously the Auckland VHF Group, NZART Branch 66 stepped forward to finance this important material which has resulted the work being completed on schedule.

Now, a lot lighter in weight, the aluminium blocks have been formed into the strong skeleton of our KiwiSAT.

Work continues with our Flatsat to prove the integrated systems.

Completion date = Work in progress apace with integration.

 

Launch Adaptor. – Prototype.

With pre flight testing now being seriously addressed, the need for a suitable test support for the satellite was identified. A number of alternatives where considered but what better than ‘the real thing” if it could be produced at a reasonable cost. From material costs there was little between any of them so a fabricated “drum” was decided upon – if facilities could be found for its manufacture. They could!

After extensive research a number of part dimensioned sketches were obtained and from these (and AMSAT photographs) a Dnepr style launch adaptor has been designed. The basic ‘drum’ shaped support was recently completed in the Massey University Engineering Workshop in Albany. It will be used to confirm our ‘fit-up’ plate and to support the flight version of the completed satellite for the pre flight vibration, shock and balance testing.

Our thanks to Dr Johan Potgieter for approving and assisting with its manufacture and in particular to Eddie Rogers (Workshop Manager) and Clinton Darsch for their skill and effort in turning the aluminium plate supplied into the superb adaptor framework pictured. Accompanying is a picture of the launch adaptor for AO-51 fitted to its Dnepr LV third stage. (Thanks, Chuck, N0ADI)

Completion date = Completed - awaiting Launch Agency approval.

 

Solar Panels

The problem of obtaining suitable high efficiency solar cells was a continuing headache until we received a heads up from David, (G0MRF) just before Christmas.

Some “substandard satellite gallium arsenide cells” had appeared on eBay. We immediately started the ball rolling to establish whether or not we would have problems under US export restrictions/ITAR in bringing the cells to New Zealand if we were to buy them. To cut a long story short; with the help of Reinhold Bauer of The Aerospace Corporation - whom I had the good fortune to meet at the Asian Space Conference in Singapore last year and who has been an absolute fund of information - and Bill (N6GHZ) of High Sierra Microwave (who had already supported us with a set of Hotweezers for the wiring loom work) we now have enough cells to complete the flight solar panels. Not only that but we can also produce one panel of each type as a spare AND we have enough to offer to another small project once ours is complete.

To both Reinhold and Bill we offer our sincere thanks for stepping up to the plate and giving KiwiSAT a magnificent start for 2008. Such effort from already busy guys is terrific. The ‘ZL hospitality suite awaits when you pay a visit to us down here!
(Ever helpful Bill has recently taken on the acquisition of suitable (slim) high quality panel connectors for connecting the solar panels to the BCR. Not only taken on but succeeded! Phenomenal, Bill.)

 

General Comment.

Science Package.

Visitors to this site will have noticed a reference to an enhancement to the satellite's systems – the addition of beacon on U Band. This we plan to use for some ionospheric Faraday Rotation experiments which – in a way – is a replacement for the ozone measurement experiment we looked at earlier as an original goal for KiwiSAT. That, we decided, was a “bridge too far” and of very limited value but the additional beacon was feasible and would give us an opportunity to use KiwiSAT for some significant experimentation related to global warming. The beacon has now been firmed up and we have had approval to use 437.425 MHz. More details of this will be given later.

This is a cutting edge endeavor and we know that the transmissions will be monitored both in and outside of the Amateur Satellite Service. Monitoring assistance will certainly be needed within AMSAT and we are hopeful that your support will be forthcoming. (The ability to receive 9600 data on 2mtrs and 70cm simultaneously plus a good sound card is expected to be the requirement – and, of course – an enquiring mind and a concern for the environment!!) It’s expected – if we can achieve assistance from many (widespread) Amateur Radio Satellite stations - the results will help us get a better understanding of some aspects of global warming and point the way to better tools for its measurement. If it does, it’s well worth the additional effort.

A vote of thanks to the RF Team – and the frequency allocation guys - for making this possible.

 

ADAC Experiment.

A vast amount of work has been put in on the ADAC package by KiwiSAT Project Team member Dr. Jon Henderson and what was very much a ‘vision’ at the start of the ’06 is now a mathematically proven system. However, though the principle of Active Magnetic Control has been established, uncertainties about its application make it absolutely vital that it be proved by means of computer simulation. This will involve marrying together three MATLAB based software components which have been individually proven and found accurate. These are: Orbit Prediction using NORAD generated KEPS, Earth Magnetic Field (strength and direction) at points along the orbit using World Magnetic Model 5/10 and the Rotational Equations of Satellite Dynamics. The integrated computer model will then enable the development and testing of robust algorithms for determining and controlling satellite attitude.

Jon’s work was the subject of a meeting at the Massey University School of Technology and Engineering on July 6th (2007) and our thanks to Professor Ian Maddox (Industrial BioScience) and Dr Tom Moir (Computer Engineering), who have offered to increase Massey’s current support effort by helping in this very complex area.

Unfortunately we have yet to identify a suitable assistant but we are confident that with Jon’s very capable direction and supervision the ‘bones’ will be fleshed out to a fully working system when a volunteer does come to light.

Whilst unfortunate it’s an ongoing problem but is far away from a disaster. Providing the hardware aspects are incorporated into the space-frame – which is well in hand – the development of the software can continue right up to and after the launch. Watch this space.

Completion date = Hardware Completed.

Software.

Attention to the software for KiwiSAT has really taken off with ideas free flowing right across the Project Team. Austin, our software (and to a large extent our computer hardware guru) has been busy developing code to operate and control the various flight equipments as they join the queue for flatsat integration. And he has at the same time been working on the flight boot-loader code. With absolute priority on the system general hardware he is very much on his own at the moment.

However, as the hardware is finished and passed for physical integration in the flatsat practically all the team will switch to the software effort. (That is “all” apart from me! As a non-software guy I can only wonder at the complexity and struggle to keep up with the detail of the task – and with the jargon!)

Unfortunately I still have to report that the problem of non availability of a proven Operating System remains with us but I’m confident an answer will be found. It has to be!

My understanding is that we just need a 100% bomb-proof boot loader to be finished and loaded into ROM memory on the satellite prior to launch. With that in place the OS can follow. As a “nuts and bolts” guy I can only take heed of that statement – and keep notching up the pacemaker as we move towards hardware completion and the establishment of a firm launch day!

(If anyone can help here with anything part prepared for an OS – or even a complete one - please let us know!)

 

Where from Here?

Complete the flatsat! - We HAVE started………………

With flight items coming on stream regularly it’s now essential that we look at the program that will take us to serious negotiation with the launch agency to put us into orbit. Initial steps have been taken as mentioned above and we are already talking to ISC Kosmotras and to our friends in SSTL who are our providing much guidance and advice on what to us is a very unfamiliar area.

Our strategy is simple. We need now to complete KiwiSAT to the point where the satellite is all ready to go. It needs to be assembled and capable of full operation using a remote “ground-station”. Hans (ZL1HB) (with Andrew Cammell doing some preliminary graphics work) is already working on a simulated power system to feed the solar cell circuits with the currents it would generate with the cells when in space and we plan to have an ‘on screen’ display that will ‘fly the satellite’ as realistically as possible whilst it’s still on the ground. Similar simulated readings from the main sensor package will add to that and fill in the gaps of the ground station telemetry display software.

The object of the exercise is to convince those we approach for support for the big one – the launch costs – that we have a viable product that is worthy of their support. It’s also to confirm in an easily understandably way that “KiwiSAT” is an Amateur Radio Satellite Service communications satellite, not an ‘amateur’ satellite with the “baggage” that could be conjured up in the minds of those that are unfamiliar with what ‘Amateur’ in terms of AMSAT is all about. This is vital. Our own confidence in our teams’ product is not enough. We have to instill that confidence in others who are able to advance the cause and put our hard work into orbit.

Update - 23 May 2009.

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